Optimising Water Treatment with Plant Design Software and Virtual Twin Technology

Bradan Water Treatment Works is a critical facility, supplying up to 120 million litres of drinking water each day to Ayrshire and Dalmellington. With raw water sourced from both Loch Bradan and Loch Derclach, the plant experiences seasonal variations in water quality and flow. Optimising the treatment process carried significant risk, as any disruption could affect water quality and service delivery. Traditional optimisation methods that required live testing were not feasible for a facility that must be operational at all times. 

 

 

GHD was engaged to develop a digital process simulation of the treatment works using EVS:Water Plant Designer, a cloud-based software that supports collaborative design and operations modelling. The software enables a single source of information across all phases of a project, automates process engineering deliverables and reduces design time through its intuitive drag-and-drop interface and automatic calibration. 

 

Using site drawings, instrumentation diagrams, SCADA data, raw water quality and mass balances, the team created a highly detailed virtual model of the facility. This digital replica allowed simulations of operational scenarios, such as asset configurations and chemical dosing adjustments, without interfering with live plant operations. 

 

Importantly, the model also allowed assessment of different feed water scenarios. With raw water coming from two sources, the team used the simulation to evaluate how variations in feed water quality, such as those caused by storms, seasonal shifts or changes in alkalinity, would affect sludge production, chemical dosing and treated water quality. The model provides granular data on chemical streams.  

The digital twin enabled Scottish Water to assess improvement opportunities safely and effectively, supporting confident decision-making without interrupting service. This approach improved understanding of how different operating conditions affect plant performance and highlighted opportunities for reducing costs, particularly in energy use and chemical dosing. The ability to simulate and refine changes in a virtual setting provided a valuable head start on future upgrades. 

GHD’s digital process modelling and virtual twin capability helps utilities manage risk, improve operational efficiency and extend the performance of critical water infrastructure. Through our Future of Water initiative, we’re helping our teams in bringing together engineering insight, process intelligence and digital tools like EVS:Water and DTO-Virtual Twin to help clients design and operate water systems that are more resilient, efficient and adaptive to change.